Having an all aluminum intercooler made...

jinstall · **Posted:** Wed Oct 17, 2012 10:12 pm

Watching this thread update.

CATCRD · **Posted:** Wed Oct 17, 2012 11:18 pm

kjjet wrote:

My intercooler was leaking all around the plastic sides. I sealed it by applying aircraft fuel tank sealant around all where the plastic and aluminum are crimped. The sealant will stay flexable for years. A all aluminum replacement would be great although it may outlast the engine.

Aircraft fuel tank sealant... that is a great idea, and not just for the intercooler. Where might one acquire some of it, and do you have a recommended type?

painemann · **Joined:** Sat Dec 20, 2008 7:02 pm **Posts:** 607

CATCRD wrote:

kjjet wrote:

My intercooler was leaking all around the plastic sides. I sealed it by applying aircraft fuel tank sealant around all where the plastic and aluminum are crimped. The sealant will stay flexable for years. A all aluminum replacement would be great although it may outlast the engine.

Aircraft fuel tank sealant... that is a great idea, and not just for the intercooler. Where might one acquire some of it, and do you have a recommended type?

Also interested in this, I used JB weld on a few leaks and I'm scared to check them now because I bet they are leaking again. JB seems too brittle for this application!

kjjet · **Posted:** Thu Oct 18, 2012 11:47 pm

The tank sealant is available thru several aviation supliers including. AVIALL, AIRCRAFT SUPPLY (Pittsburgh) Cosgrove aircraft supply (NY), All will ship to you. It seals out most anything as long as the surface is clean and dry. Any questions PM me. Appliations are endless.

GreenDieselEngineering · **Joined:** Sun Jun 07, 2009 5:10 pm **Posts:** 1111

We would like to get one of these as well. Mainly to measure the pressure drop and thermal gradient as compared to the stock CAC data recorded when our tunes were developed. A better intercooler could further add to the fuel economy if matched with optimized boost pressure settings and vane position on turbo.

LMWatBullRun · **Posted:** Fri Oct 19, 2012 10:46 am

I would be interested in pressure drop/flow data, and assuming this shows better than stock performance, would be interested in purchasing one, too.

skates04 · **Posted:** Fri Oct 19, 2012 11:10 am

That is a very good price on an aluminum intercooler! Especially for one custom made. Any chance they will be any cheaper once the jig is made?

ROCK! · **Joined:** Sat Dec 18, 2010 3:38 pm **Posts:** 156

I'm very interested! Mine is leaking, and there's no way I'm spending $700 on another plastic junker. I'll be watching this thread, and patiently waiting for your pix/results. :POPCORN:

ChooChooman74 · **Posted:** Thu Nov 22, 2012 7:22 pm

Bump!

Any updates?

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arengant · **Posted:** Mon Nov 26, 2012 3:28 am

Now subscribing...

UFO · **Posted:** Tue Nov 27, 2012 1:34 pm

audiboy86 wrote:

I am in on one if you can make it fit and if doesn't cause to much extra lag because of the larger capacity.

Lag due to intercooler volume and pipe sizing is a complete myth. If you do the math, given the volume of air the engine ingests, the time lag involved is in the tens of milliseconds, unmeasurable to your lag "calculator".

BlackSkyRacing · **Posted:** Sat Dec 08, 2012 4:12 pm

Sorry guys, got side tracked at the shop and my supplier got hit by Sandy... Kinda hard to weld with no power. He has to track down a new core as the one he acquired got water damaged and so did his supplier's stock. My wife's Jeep is back on the road with a stock intercooler for now

BTW anybody else have any issues with sticky vanes in the turbo if it sat for an extended period of time? Seems my wife's turbo is stuck open so it's throwing underboost codes. Guess I'll have to remove it and disassembe it for a good cleaning. :banghead:

NotPicky · **Posted:** Sat Dec 08, 2012 4:32 pm

Will the stock intercooler even take 30psi? Mine hasn't leaked yet but once the tranny is installed, I'm continuing with turbo upgrade. Just curious. So ya I'm very interested in a all aluminum intercooler if the stocker won't hold.

BlackSkyRacing · **Posted:** Sat Dec 08, 2012 5:55 pm

NotPicky wrote:

Will the stock intercooler even take 30psi? Mine hasn't leaked yet but once the tranny is installed, I'm continuing with turbo upgrade. Just curious. So ya I'm very interested in a all aluminum intercooler if the stocker won't hold.

I'd rather not find out... Wish I knew these suckers could handle some boost, I have a nice HY35 sitting on the floor in the shop. I'd love to compound this sucker and have my injector supplier make me some nozzles. Though I think at that point anything behind the transmission would most definitely hate life.

NotPicky · **Posted:** Sat Dec 08, 2012 11:22 pm

BlackSkyRacing wrote:

Wish I knew these suckers could handle some boost, I have a nice HY35 sitting on the floor in the shop. I'd love to compound this sucker and have my injector supplier make me some nozzles. Though I think at that point anything behind the transmission would most definitely hate life.

I agree to that. If you want to compound get rid of the gt2056vgt. I've built a T3 Flanged manifold for mine. Waiting on a new BB center section for my gt2560r. Starting off with a non wastegated housing. Let me know on those nozzles I'm interested in a set of them. That poor transfer case and 8.25 rear end.

What do you think the cost will be on Intercooler (ballpark)?

geordi · **Posted:** Sun Dec 09, 2012 1:59 am

I think adding excess boost to these is a dangerous idea. People on the TDI forums talk about damaging the bottom end with too much boost. Based on my own experiences with STOCK boost and only occasional overboost codes (fast spikes to no more than 27psi) it makes me VERY nervous to think about anyone trying compound turbos or other crazy stuff.

I think more air might not be the worst, but are you really certain the bottom end can hold it?

LMWatBullRun · **Posted:** Sun Dec 09, 2012 5:56 pm

I am not interested in running overboost on the CRD, but in getting components that will last half a million miles, not just till the warranty runs out. An AL intercooler would seem to have the requisite potential.

geordi · **Posted:** Sun Dec 09, 2012 6:51 pm

LMWatBullRun wrote:

I am not interested in running overboost on the CRD, but in getting components that will last half a million miles, not just till the warranty runs out. An AL intercooler would seem to have the requisite potential.

That would be my reason for using it as well - I want a vehicle (especially if it is a Jeep, meant to be used hard) to have bulletproof components. For stock boost, etc... An Al intercooler is a great step to that goal.

LMWatBullRun · **Posted:** Sun Dec 09, 2012 10:09 pm

geordi wrote:

LMWatBullRun wrote:

I am not interested in running overboost on the CRD, but in getting components that will last half a million miles, not just till the warranty runs out. An AL intercooler would seem to have the requisite potential.

That would be my reason for using it as well - I want a vehicle (especially if it is a Jeep, meant to be used hard) to have bulletproof components. For stock boost, etc... An Al intercooler is a great step to that goal.

I should have said, Geordi, that I agree with you on the inadvisability of overboosting.

BlackSkyRacing · **Posted:** Mon Dec 10, 2012 10:46 am

NotPicky wrote:

BlackSkyRacing wrote:

Wish I knew these suckers could handle some boost, I have a nice HY35 sitting on the floor in the shop. I'd love to compound this sucker and have my injector supplier make me some nozzles. Though I think at that point anything behind the transmission would most definitely hate life.

I agree to that. If you want to compound get rid of the gt2056vgt. I've built a T3 Flanged manifold for mine. Waiting on a new BB center section for my gt2560r. Starting off with a non wastegated housing. Let me know on those nozzles I'm interested in a set of them. That poor transfer case and 8.25 rear end.

What do you think the cost will be on Intercooler (ballpark)?

Hahaha, I worry about that poor little 8.25 as is... Someday I'll swap the 8 3/4 I have laying around under there. Sounds as though I'll likely leave this particular Jeep's turbo alone if 27psi spikes have made educational see through blocks, since this is my wife's baby. I do want to pick one up for the shop though, these things are nice for parts running.

Cost is uncertain right now, it really depends on what he charges for all the tabs and mounts. He said the core and tanks should run around $500. Like I said, it's likely to be around that $700 range, shipping should be around $50 as it cost me $40 to send the stocker to him in a way oversized box that I packed, whereas he uses a shipping service that packages them for him.

Having an all aluminum intercooler made...

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